Advances in Manufacturing最新文献

{"title":"Holistic high-temperature assistance for laser directed energy deposition of Al2O3/ZrO2 eutectic ceramics: cracking behavior","authors":"Dong-Jiang Wu,&nbsp;Cheng-Xin Li,&nbsp;Ming-Ze Xu,&nbsp;Xue-Xin Yu,&nbsp;Guang-Yi Ma,&nbsp;Huan-Yue Zhang,&nbsp;Cong Zhou,&nbsp;Bi Zhang,&nbsp;Fang-Yong Niu","doi":"10.1007/s40436-025-00572-x","DOIUrl":"10.1007/s40436-025-00572-x","url":null,"abstract":"<div><p>Laser-directed energy deposition (LDED) has emerged as a primary technology for the direct additive manufacturing of melt-growth ceramics (MGCs). However, cracking during fabrication severely limits further development of this technology. This study investigated a new holistic high-temperature-assisted method for LDED to solve the cracking problem. This method mitigates the high temperature gradients caused by the low thermal conductivity of the material during fabrication, thereby suppressing crack formation. The LDED of Al₂O₃/ZrO₂ eutectic ceramics was performed at a holistic auxiliary temperature of up to 1 273 K, and the crack-suppressing effectiveness and mechanism were verified by combining numerical simulations and experiments. The results demonstrated that holistic high-temperature assistance significantly mitigated cracking in Al₂O₃/ZrO₂ eutectic ceramics fabricated via LDED. At an auxiliary temperature of 1 273 K, the stress level in the fabricated sample was reduced by an order of magnitude compared to that at room temperature. Consequently, the lengths and densities of the cracks in the fabricated samples decreased by 47.6% and 55.6%, respectively. This study confirmed that the holistic high-temperature-assisted LDED method could play an important role in the additive manufacturing of low-ductility materials.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 2","pages":"474 - 498"},"PeriodicalIF":3.8,"publicationDate":"2025-11-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147733191","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Theoretical and experimental study of the evolution of surface textures during wheel polishing with fluid cutting model","authors":"Yi-Fan Zhu,&nbsp;Peng-Feng Sheng,&nbsp;Qiu-Shi Huang,&nbsp;Li Wang,&nbsp;Jun Yu,&nbsp;Zhong Zhang,&nbsp;Zhan-Shan Wang","doi":"10.1007/s40436-025-00574-9","DOIUrl":"10.1007/s40436-025-00574-9","url":null,"abstract":"<div><p>Metal mirrors with ultra-smooth surfaces have a wide range of applications in X-ray and other optics. The fabrication of X-ray mirrors usually requires high-precision turning and grinding, which has a periodic texture with anisotropic characteristics. To obtain a stable low roughness surface over the full-aperture surface, it is crucial to study the evolution law of these textures during polishing. In this article, a model for the evolution of periodic texture roughness based on contact mechanics and fluid micro-cutting has been established. It was found that the fluid cutting stress caused by the periodic texture orientation had a significant impact on the evolution of roughness. When the orientation of periodic texture is perpendicular to the rotation direction of polishing wheel, the contribution of fluid micro-cutting to the evolution of the roughness reaches its maximum. The evolution speed of surface roughness is the fastest. Polishing experiments using single direction rotating wheel on turned electroless nickel plate were performed to verify the theory. The experimental results were in good agreement with the theoretical results. This work shows that the fluid micro-cutting plays an important role in the evolution of periodic texture roughness. It provides useful guidance for full-aperture polishing of anisotropic textures.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 2","pages":"294 - 310"},"PeriodicalIF":3.8,"publicationDate":"2025-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147733189","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Removal mechanism of RB-SiC using axial ultrasonic-assisted scratching","authors":"Zhi-Gang Dong,&nbsp;Bao-Rong Li,&nbsp;Zhong-Wang Wang,&nbsp;Xiao-Guang Guo,&nbsp;Jian-Song Sun","doi":"10.1007/s40436-025-00573-w","DOIUrl":"10.1007/s40436-025-00573-w","url":null,"abstract":"<div><p>Reaction bonded silicon carbide (RB-SiC) is widely used in the aerospace industry because of its excellent physical and mechanical properties. However, owing to its high hardness and wear resistance, achieving the precise machining of RB-SiC has become a challenge. Ultrasonic-assisted grinding technology has the potential to significantly enhance machining efficiency and minimize surface damage when machining hard and brittle materials. This method is widely considered the optimal approach for machining RB-SiC. Investigating the material-removal mechanism in ultrasonic-assisted grinding is crucial for promoting the application of this technology. A finite element simulation and an experiment on the axial ultrasonic-assisted scratching of RB-SiC were performed, and the material-removal behavior in the ultrasonic-assisted grinding process was studied. Changes in the cross-sectional profile, scratch force, material-removal ability, and surface morphology of the scratches at different scratch depths and ultrasonic amplitudes were compared and analyzed. The effects of axial ultrasonic vibration on the removal behavior of RB-SiC materials were discussed in combination with the strain rate and crack propagation behavior. Compared with conventional scratching, axial ultrasonic-assisted scratching effectively decreased the scratching force and increased the material-removal ability. The maximum reduction value of normal scratching force was 56.73%. The material-removal ability could even reach 24.04 times, which could significantly improve the processing efficiency. The research conducted in this study offers theoretical guidance for understanding the mechanism of damage formation and suppression strategies to control it in the ultrasonic-assisted grinding of RB-SiC.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 2","pages":"416 - 436"},"PeriodicalIF":3.8,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147733085","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation into material removal mechanism of high-volume-fraction SiCp/Al composite by fast ED milling","authors":"Jun-Cheng Lu,&nbsp;Jian Wang,&nbsp;Qiang Gao,&nbsp;Qian Zheng,&nbsp;Yi-Fan Lu,&nbsp;Ya-Ou Zhang,&nbsp;Wan-Sheng Zhao","doi":"10.1007/s40436-025-00575-8","DOIUrl":"10.1007/s40436-025-00575-8","url":null,"abstract":"<div><p>High-volume-fraction SiC particle-reinforced aluminum (SiCp/Al) metal matrix composites (MMCs) are widely utilized in the electronic packaging of aerospace equipment because of their low density and high thermal conductivity. However, the extremely high hardness of SiC and compact structure of electronic packaging components pose significant challenges to conventional manufacturing techniques. Severe tool wear can reduce the processing efficiency and increase the manufacturing costs. Therefore, this work introduces a fast electrical discharge (ED) milling approach for machining high-volume-fraction SiCp/Al MMCs. This method was successfully applied to the fabrication of gas-film holes. Nevertheless, Ni-based superalloys differ significantly from SiCp/Al, and their material-removal mechanisms and machining capabilities represent core knowledge gaps. Consequently, this study employed an observation setup based on a high-speed camera to capture the gap discharge phenomenon and analyze the machined surfaces and generated debris. This analysis revealed the material-removal processes and mechanisms under two processing conditions with pulse durations of 50 μs and 500 μs. Additionally, the capability of fast ED milling to process high-volume-fraction SiCp/Al MMCs was initially verified through sample machining. The experimental results demonstrated that this method could create parts with complex and precise geometries, achieving satisfactory results in terms of machining accuracy and surface quality. Dimensional errors could be controlled within  ± 50 μm, and the average surface roughness was less than 3 μm.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 2","pages":"397 - 415"},"PeriodicalIF":3.8,"publicationDate":"2025-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147733084","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Data-driven optimization of frozen sand mold cryogenic cutting process parameters for cutting energy and tool wear reduction","authors":"Jian-Pei Shi,&nbsp;Zhong-De Shan,&nbsp;Hao-Qin Yang,&nbsp;Jian Huang","doi":"10.1007/s40436-025-00571-y","DOIUrl":"10.1007/s40436-025-00571-y","url":null,"abstract":"<div><p>Green manufacturing prioritizes quality, efficiency, low energy consumption, and cleanliness in milling technology. Consequently, a data-driven optimization method was proposed for configuring multiple technological parameters in frozen sand molds, to reduce energy consumption and tool wear during processing. Initially, a power composition model for frozen sand mold processing was developed, based on an analysis of the relationship between the energy consumption and various actions during different processing states. Subsequently, using Archard wear theory, a discrete element model for cutting frozen sand molds was established to investigate the wear characteristics of flat-end milling tools influenced by multiple factors. The cutting wear of the frozen sand mold presents as a continuous abrasive wear form at polycrystalline diamond (PCD) cutting edge and the side end of the tool shank. Comprehensive experiments were conducted to develop a Kriging energy consumption model and radial basis function model for tool wear based on varying cutting technological parameters. The accuracy of the developed surrogate model was confirmed using an optimal Latin hypercube experimental design and leave-<i>p</i>-out cross-validation (LPOCV). Analysis of the technological parameters revealed that the milling speed and feed rate per tooth significantly affected both milling power and tool wear. Finally, the surrogate model was integrated with particle swarm optimization and a genetic algorithm to solve for the Pareto frontier and identify the optimal combination of cutting parameters. The optimized parameters of the multi-objective model reduced the milling power by 29.88% and tool wear by 18.18% during the processing of frozen sand molds. The models proposed for the milling power and tool wear in this study are accurate and reliable. By revealing the mapping relationship among the cutting power, tool wear and various cutting parameters, the proposed model can serve as an excellent platform for the energy-saving manufacturing of frozen sand molds.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 2","pages":"452 - 473"},"PeriodicalIF":3.8,"publicationDate":"2025-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147733190","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Pyramid-based anti-fisheye feature enhancement preprocessing algorithm in torpedo can electrical devices: application in steel rolling process","authors":"Tian-Jie Fu,&nbsp;Shi-Min Liu,&nbsp;Pei-Yu Li,&nbsp;Ruo-Xin Wang","doi":"10.1007/s40436-025-00569-6","DOIUrl":"10.1007/s40436-025-00569-6","url":null,"abstract":"<div><p>The steel manufacturing industry currently urgently needs highly accurate detection algorithms for electrical connection devices to slow down the time and danger of electrical connections to torpedo cans during high-temperature operations. The fisheye effect and fuzzy features of industrial cameras seriously affect accuracy and effectiveness, hindering the widespread application of object detection algorithms in the manufacturing industry. We propose a feature enhancement preprocessing algorithm for torpedo can electrical devices based on the pyramid structure that resists fisheye effects and serves to detect and locate electrical connection devices. With the aid of this preprocessing algorithm, the detection efficiency and accuracy of state-of-the-art (SOTA) object detection models are significantly improved. Experimental validation confirms the superiority of our method over other SOTA methods. With the application of our preprocessing algorithm, the production capacity of the steel plant increased by 31.8%, and material wastage caused by transportation decreased by 10.9%.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 2","pages":"329 - 342"},"PeriodicalIF":3.8,"publicationDate":"2025-09-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40436-025-00569-6.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147733087","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Complete coverage path planning for multi-connected free-form surface grinding based on reinforcement learning","authors":"Zhen Zhu,&nbsp;Bing-Zhou Xu,&nbsp;Chang-Qing Shen,&nbsp;Xiao-Jian Zhang,&nbsp;Si-Jie Yan,&nbsp;Han Ding","doi":"10.1007/s40436-025-00570-z","DOIUrl":"10.1007/s40436-025-00570-z","url":null,"abstract":"<div><p>Coverage path planning (CPP) is an essential process in robotic grinding, particularly with the increasing demand for large-scale multiconnected free-form surfaces, such as high-speed rail shells, car shells, and aeronautical parts. Owing to its multi-connectivity, achieving full coverage with a single continuous path is challenging. Additionally, large curvatures make the path spacing difficult to control, leaving some areas uncovered. Existing methods often fail to optimize continuity and coverage rates simultaneously, resulting in redundant tool-feeding and lifting processes that significantly reduce processing efficiency. Thus, a novel method for free-form surface CPP is proposed based on reinforcement learning (RL), which enables the learning of an optimal path with optimized continuity and coverage rates. Specifically, to regulate the path spacing, a uniform grid map is constructed based on the least-squares conformal mapping (LSCM) method, which parameterizes the grinding surface to a two-dimensional (2D) plane with controllable distortion. Furthermore, a CPP-specific evaluation criteria (CEC) is designed to evaluate the path through various key factors, including coverage rate, continuity, and smoothness. Finally, a grinding path is generated using the CEC-guided RL framework. The method was verified through several simulations, and a grinding experiment on a high-speed rail head surface was conducted as a typical application. The results showed high path continuity and coverage rates, demonstrating its potential for addressing CPP problems in different manufacturing scenarios.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 2","pages":"359 - 376"},"PeriodicalIF":3.8,"publicationDate":"2025-08-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147733089","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"High-performance nano-PTFE reinforced nickel mold for defect-free micro injection molding of surface micro structures","authors":"Tian-Yu Guan,&nbsp;Quan-Liang Su,&nbsp;Ri-Jian Song,&nbsp;Rong-Cheng Gan,&nbsp;Yi-Xin Chen,&nbsp;Feng-Zhou Fang,&nbsp;Nan Zhang","doi":"10.1007/s40436-025-00568-7","DOIUrl":"10.1007/s40436-025-00568-7","url":null,"abstract":"<div><p>Interest in electroformed nickel (Ni) molds has continued increasing due to their high precision, low cost and high surface finish. Nevertheless, pure Ni molds still rely on extra surface treatments employing release agents to achieve defects-free demolding and meanwhile, mitigate the residual contamination. To address these issues, lubricant-retaining Ni mold was achieved by doping low surface tension polytetrafluoroethylene (PTFE) nano-fillers into the Ni matrix via electrodeposition. The introduction of surfactant mixtures facilitated the successful incorporation of PTFE into the Ni matrix, causing them to perfectly integrate and form as a whole. Such mold exhibited excellent mechanical performance with the enhanced hardness of 452 HV (2.3-fold increase), low surface roughness of 23 nm in <i>S</i>_a and low surface energy of 28.1 mJ/m² (33.6% decrease), resulting in a maximum reduction of 28.6% in demolding force. This Ni-PTFE mold can withstand more than 1 500 demolding cycles without the need for additional demolding agents or the removal of residual contaminants. Importantly, no PTFE nanoparticles were detected on the produced cyclic-olefin-copolymer (COC) chips, as confirmed by energy dispersive X-ray spectroscopy analysis and Raman spectroscopy, confirming no contamination to the polymer and no lubrication degradation of such mold. Polymer chips produced from such mold displayed well-defined structures and excellent biocompatibility, rendering them suitable for microfluidic applications. Finally, this facile and cost-effective method enables creating a reusable, high-resolution mold with low surface energy, ensuring defects-free demolding for the mass production of polymer parts.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 2","pages":"274 - 293"},"PeriodicalIF":3.8,"publicationDate":"2025-07-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40436-025-00568-7.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147733034","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Green machining technology and application driven by digital intelligence: a review","authors":"Tai-Min Luo,&nbsp;Jin Zhang,&nbsp;Chen-Jie Deng,&nbsp;Dai-Xin Luo,&nbsp;Gui-Bao Tao,&nbsp;Hua-Jun Cao","doi":"10.1007/s40436-025-00567-8","DOIUrl":"10.1007/s40436-025-00567-8","url":null,"abstract":"<div><p>With the continuous advancement of science and technology, alongside the increasing significant attention within the manufacturing industry, high-performance demands are placed on advanced equipment and components because of extreme temperatures, heavy impact loads, and other challenging operating conditions. The importance of resource conservation and environmental preservation is becoming more widely recognized. This paper reviews green machining technology, driven by digital intelligence. Initially, the background of green machining powered by digital technologies is introduced, focusing on digitalization, intelligence, and sustainability as key factors for improving machining efficiency, enhancing product performance, and minimizing both energy consumption and environmental pollution. Subsequently, the paper elaborates on the current research and development in digital intelligence-driven green machining technologies, highlighting four critical areas: smart toolholders, minimal quantity lubrication (MQL), machine tool compensation, machine tool energy consumption monitoring, and intelligent carbon emission control. Lastly, the future trends and challenges in these technologies are discussed, with an outlook on the growing importance of green machining in response to technological advancements and evolving market demands.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 :","pages":"43 - 102"},"PeriodicalIF":3.8,"publicationDate":"2025-07-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147337812","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Machine learning-assisted surrogate model for developing MIMO quantitative relationship in plastic injection molding","authors":"Yan-Ning Sun,&nbsp;Hai-Bo Qiao,&nbsp;Zeng-Gui Gao,&nbsp;Li-Lan Liu,&nbsp;Wei Qin","doi":"10.1007/s40436-025-00560-1","DOIUrl":"10.1007/s40436-025-00560-1","url":null,"abstract":"<div><p>Plastic injection molding (IM) is a typical multiple-input multiple-output (MIMO) complex manufacturing process widely used in modern industrial production. Determining the critical process parameters and establishing the MIMO quantitative relationship between them and the plastic product quality are two fundamental problems in IM process decision analytics. Focusing on high-dimensional process parameters and multidimensional quality indicators in the IM process, this study developed a machine learning-assisted surrogate model that integrated joint mutual information (JMI) and multi-output support vector regression (MSVR). Firstly, a JMI-based sequential search algorithm was developed to measure the association relationship between each process parameter and a multidimensional quality indicator set, and automatically select the critical process parameters of the IM process. It can effectively filter redundant information from raw industrial datasets and provide essential input features for the development of surrogate models. The MSVR model was then developed to capture the MIMO quantitative relationship between the selected critical process parameters and multidimensional quality indicator set. The proposed method can preserve complete independent variable information and avoid losing the relevance of data during training. Finally, the effectiveness of the model was verified using a real-world IM process dataset.</p></div>","PeriodicalId":7342,"journal":{"name":"Advances in Manufacturing","volume":"14 2","pages":"514 - 528"},"PeriodicalIF":3.8,"publicationDate":"2025-07-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147733090","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}